1. Design & Manufacture of Rotorcraft IME Team#8/ME Team#31 Chabely Amo Louisny Dufresne Robert Johnson Mohammed Nabulsi Taniwa Ndebele Victoria Rogers Kimberlee Steinman Mitchell Stratton IME Team #8/ME Team #31 Slide 1 of 32 Kimberlee Steinman Design & Manufacture of Rotorcraft

2. Team Organization IME Team #8/ME Team #31 Slide 2 of 32 Kimberlee Steinman Design & Manufacture of Rotorcraft

3. Background IME Team #8/ME Team #31 Slide 3 of 32 Kimberlee Steinman Design & Manufacture of Rotorcraft A rotorcraft is a flying machine that uses lift generated by wings called rotor blades that revolve around a mast Rotary unmanned aerial vehicles often fall into one of two classifications:  High payload capacity but low portability  High portability but a reduced payload capacity. Figure 1. Example of a Quad-rotor [1]

4. SWOT Analysis Quadrants IME Team #8/ ME Team #31 Slide 4 of 32 Kimberlee Steinman Design & Manufacture of Rotorcraft StrengthsWeaknesses Interdisciplinary Group Open Communication Stakeholders and Resources Large Group Limited Literature Availability OpportunitiesThreats Increase in Military Demand for Rotorcrafts Another funded group developing a similar rotorcraft might devalue the results of the project

5. SIPOC Analysis Chart IME Team #8/ME Team #31 Slide 5 of 32 SuppliersInputProcessOutputCustomers HPMI, Online retailers, College of Engineering departments. Group member's knowledge and training in design and manufacturing Design a rotorcraft that meets the customer's requirements and the manufacturing processes required to create the rotorcraft Rotorcraft matching our projects goal statement The Department of Industrial and Manufacturing Engineering and Dr.Okoli Kimberlee Steinman Design & Manufacture of Rotorcraft

6. Goal Statement and Objective Design a rotorcraft that can:  Fit in a military backpack (23”x14.5”x15”)  Carry a payload of at least 50 pounds  Be made with commercial off the shelf (COTS) components  Travel up to approximately 1 mile  Be easily maintained and used in the field Design the manufacturing processes to be used in creating the rotorcraft Build a prototype of the rotorcraft IME Team #8/ ME Team #31 Slide 6 of 32 Figure 2. Military Backpack [2] Kimberlee Steinman Design & Manufacture of Rotorcraft

7. House Of Quality Chabely Amo Design & Manufacture of Rotorcraft IME Team #8/ ME Team #31 Slide 7 of 32

8. Multi-copter Configuration IME Team #8/ ME Team #31 Slide 8 of 32 Chabely Amo Design & Manufacture of Rotorcraft Two types: 1.Coaxial Setup (X8)  Two engines mounted co-axially on the ends of each boom  Excellent Lifting Power  Easier Portability 2.Radial Setup (V8)  One engine mounted on the end of each boom Figure 3. Multi-copter Configurations [3]

9. Designs Analyses and Comparisons IME Team #8/ME Team #31 Slide 9 of 32 Chabely Amo Design & Manufacture of Rotorcraft Design #1  Proposed by Intern Student Cameron Alexander Design #2  Proposed by the Team Design #3  Proposed by the Team

10. General Design IME Team #8/ ME Team #31 Slide 10 of 32 Chabely Amo Design & Manufacture of Rotorcraft Figure 4. Cameron’s Radial DesignFigure 5. Team’s Coaxial Designs 2 and 3

11. Measure Phase Tool: eCalc Analysis Provides web-based quality services to calculate evaluate and design electric motor driven systems for remote controlled models Provides Rotorcraft outcome based on: Battery Speed Controller Motor Propeller Guarantees error margin no greater than ±10% IME Team #8/ME Team #31 Slide 11 of 32 Mohammed Nabulsi Design & Manufacture of Rotorcraft

12. eCalc Multi-Copter Calculator IME Team #8/ME Team #31 Slide 12 of 32 Mohammed Nabulsi Design & Manufacture of Rotorcraft

13. Motor Comparison IME Team #8/ ME Team #31 Slide 13 of 32 Mohammed Nabulsi Design & Manufacture of Rotorcraft DesignMotor Kv (RPM/V) Prop Range Mass (Lbs.) Max Current (A) Max Voltage (V) Power (W) Cost ($) Design #1 E-Flite Power 52 Brushless Outrunner [6] 590 12”x 8” to 14”x 7” 0.7765221650109 Design #2 E-Flite Power 360 Brushless Outrunner [5] 180 24”x10” to 25”x12” 2.713044.46000359 Design # 3 E-Flite Power 110 Brushless Outrunner [4] 295 17”x8” to 19”x10” 1.16538.42000139

14. Battery Comparison IME Team #8/ ME Team #31 Slide 14 of 32 Mohammed Nabulsi Design & Manufacture of Rotorcraft DesignBattery Capacity (mAh) Voltage (V) Discharge (C) Weight (Lbs.) Cost ($) Design #1 E-Flight Lipo Pack [9] 3,200 22.2 301.49100 Design #2 Thunder Power Lipo Pack [8] 5,000 33.3 702.56419 Design #3 Pulse Lipo Pack [7]5,000 25.9 652.09196

15. Propeller Comparison IME Team #8/ ME Team #31 Slide 15 of 32 Mohammed Nabulsi Design & Manufacture of Rotorcraft DesignPropellerProp Size Weight (Lbs.) Cost ($) Design #1Plastic [12] 16.5”x10” 0.177 Design #2 APC Electric [11] 24”x12” 0.1919 Design #3 APC Electric [10] 18”x10” 0.188

16. eCalc Results DesignLift Payload of 50 Lbs.Comments Design #1No -Maximum current is over the limit for the speed controller and the motor -Motor overheat potential -Throttle at 100% (minimal maneuverability) Design #2Yes-Throttle at 77% (full maneuverability) Design #3Conditionally-Throttle at 98% (minimal maneuverability) IME Team #8/ ME Team #31 Slide 16 of 32 Mohammed Nabulsi Design & Manufacture of Rotorcraft

17. Does it Fit in the Backpack? IME Team #8/ ME Team #31 Slide 17 of 32 Taniwa Ndebele Design & Manufacture of Rotorcraft Design Fit in the Military Backpack Design #1YES Design #2NO Design #3YES

18. Rotorcraft Simulation IME Team #8/ ME Team #31 Slide 18 of 32 Taniwa Ndebele Design & Manufacture of Rotorcraft

19. Design Cost Comparison IME Team #8/ ME Team #31 Slide 19 of 32 Taniwa Ndebele Design & Manufacture of Rotorcraft

20. Overall Designs Comparisons Design Design #1 Design #2 Design#3 LiftPayload of 50 lbs. NO YES Conditionally Fit in the Military Backpack YES NO YES Estimated Weight (lbs.) 32 47 38 Cost ($) 3841 7451 3645 IME Team #8/ ME Team #31 Slide 20 of 32 Taniwa Ndebele Design & Manufacture of Rotorcraft 2630

21. Stress Analysis Assume arms and base plate will be carbon fiber Attach 50 pound load to rotorcraft Team’s analysis shows amount of deformation under load in mm Cameron Alexander’s analysis shows yield stress Neither design fails stress analysis IME Team #8/ ME Team #31 Slide 21 of 32 Victoria Rogers Design & Manufacture of Rotorcraft

22. Base Plate Stress Analysis Comparison IME Team #8/ ME Team #31 Slide 22 of 32 Victoria Rogers Design & Manufacture of Rotorcraft Team’s DesignCameron Alexander’s Design Bottom View with Hook Top View without Hook

23. Arms Stress Analysis Comparison IME Team #8/ ME Team #31 Slide 23 of 32 Victoria Rogers Design & Manufacture of Rotorcraft Team’s DesignCameron Alexander’s Design

24. Microcontroller Unit (MCU)  “Brain” of Rotorcraft  Controls all main functions  Code is stored here  All inputs and outputs move through the MCU  Will be placed inside the frame  Prevents crash damage  Kept safe from adverse weather  Helps to maintain balance of craft  Light relative to other parts IME Team #8/ ME Team #31 Slide 24 of 32 Mitchell Stratton Design & Manufacture of Rotorcraft Figure 6. Brain of Rotorcraft

25. Arduino Leonardo 20 Digital I/O Ports 12 Analog inputs C++ Programming Language Compatible with IMU IME Team #8/ ME Team #31 Slide 25 of 32 Figure 7. Arduino Leonardo [13] Mitchell Stratton Design & Manufacture of Rotorcraft Voltage (V)Cost ($)Size (in)Weight (g) 7 – 12232.7 x 2.120

26. Inertial Measurement Unit (IMU) Contains:  Gyroscope  Accelerometer  Compass Responsible for Providing orientation data to the MCU Keeps rotorcraft straight IME Team #8/ ME Team #31 Slide 26 of 32 Figure 8. Flight Control Panel Mitchell Stratton Design & Manufacture of Rotorcraft

27. Adafruit 9-DOF IMU Breakout Compatible with Arduino Leonardo L3DG20H gyroscope LSM303DLH accelerometer/compass 3V regulator IME Team #8/ ME Team #31 Slide 27 of 32 Robert Johnson Design & Manufacture of Rotorcraft Figure 9. Adafruit 9-DOF IMU [13] Cost ($)Size (in)Weight (g) 29.951.5 x 0.92.8

28. RC Controller Input for electrical design Must have unique frequency  Limits interference IME Team #8/ ME Team #31 Slide 28 of 32 Figure 10. RC Controller Robert Johnson Design & Manufacture of Rotorcraft

29. Design Flow IME Team #8/ ME Team #31 Slide 29 of 32 IMU RC Controller MCU Rotors Robert Johnson Design & Manufacture of Rotorcraft

30. Schedule: Gantt Chart IME Team #8/ ME Team #31 Slide 30 of 32 Louisny Dufresne Design & Manufacture of Rotorcraft

31. Conclusion Objective: Design and Manufacture a Rotorcraft that can:  Fit in a military backpack (23x14.5x15)  Can carry a payload of at least 50 pounds  Made with COTS components (off the shelf)  Has a range of approximately 1 mile  Easy to maintain and use in the field What’s Next:  Analyze Phase  Build and Manufacture Design #3  Perform Ergonomics Analysis IME Team #8/ ME Team #31 Slide 31 of 32 Louisny Dufresne Design & Manufacture of Rotorcraft

32. References [1] "FlightGear Forum View Topic - Four Rotor Helicopter." FlightGear Forum View Topic - Four Rotor Helicopter. PhpBB Group, n.d. Web. 02 Dec. 2014. [2] "SMALL MOLLE ASSAULT BACKPACK MILITARY RUCKSACK ARMY NEW." eBay. N.p., n.d. Web. 22 Oct. 2014.. [3] "Multi-Rotor Frame Configurations - CopterCraft.com." CopterCraftcom RSS2. Web. 30 Nov. 2014.. [4] "Power 110 Brushless Outrunner Motor, 295Kv." (EFLM4110A): E-flite. Web. 30 Nov. 2014.. [5] "Power 360 Brushless Outrunner Motor, 180Kv." (EFLM4360A): E-flite. Web. 30 Nov. 2014.. [6] "Power 52 Brushless Outrunner Motor, 590Kv." (EFLM4052A): E-flite. Web. 30 Nov. 2014.. [7] "Lithium Polymer Battery." Wikipedia. Wikimedia Foundation, 29 Nov. 2014. Web. 30 Nov. 2014.. [8] "Pulse Battery." Pulse Battery. Web. 30 Nov. 2014.. [9] "Thunder Power RC G8 Pro Force 70C 5000mAh 9-Cell/9S 33.3V LiPo Battery FREE SHIPPING SKU: TP5000-9SPF70." RCToyscom New Products. Web. 30 Nov. 2014.. [10] "APC APCE-18X10, APCE 18X10, Accessories." APC APCE-18X10. Web. 30 Nov. 2014.. [11] "APC APCE-24X12, APCE 18X10, Accessories." APC APCE-18X10. Web. 30 Nov. 2014.. [12] "USA DEALS." 2Pcs 16.5 X 10 Black Plastic Folding Propeller Blade for RC Helicopter. Web. 30 Nov. 2014.. [13] "How To Build A Quadcopter." THE WORLD FROM MY POINT OF VIEW. N.p., n.d. Web. 22 Oct. 2014.. IME Team #8/ ME Team #31 Slide 32 of 32 Louisny Dufresne Design & Manufacture of Rotorcraft